Wall construction



Se t. 23, 1969 c. J. MILLER WALL CONSTRUCTION 3 Sheets-Sheet 1 FiledApril 14, 1966 nim ll lli]!!!H I RM m k M M ATTORNEYS Sept. 23, 1969 c.J. MILLER WALL CONSTRUCTION 3 Sheets-Sheet 2 Filed April 14, 1966 a IINVENTOR. UlaLmmJMiLlar ATTORNEYS Sept. 23, 1969 c. J. MILLER WALLconsmucnou 3 Sheets-Sheet 5 Filed April 14, 1966 INVENTOR. ClearanceJNv'ller 9W &

ATTORNEYS United States Patent O 3,468,088 WALL CONSTRUCTION Clarence J.Miller, 1822 28th St. NW., Canton, Ohio 44709 Filed Apr. 14, 1966, Ser.No. 542,542 Int. Cl. E04b 1/00, 2/00 U.S. Cl. 52-250 Claims ABSTRACT OFTHE DISCLOSURE The invention relates to a method of making pouredconcrete wall srtuctures either above or below ground level, usingrelatively simple and easily erected form means. More particularly theinvention relates to a procedure for erecting concrete walls involvingthe provision and use of relatively flexible forms which may or may notbe removed after concrete has been poured within, contained within, andset in cavities provided by the flexible form means; and to form meansused to practice the improved methods.

Heretofore concrete wall structures, whether or not reinforced, usuallyhave been built by erecting either wooden or metal forms maintainedspaced apart to provide the desired wall thickness. Such forms wererelatively rigid to provide a cavity of predetermined volume and havingpredetermined surface locations. Such forms normally were removed afterthe concrete was poured and had set.

The provision and erection of such prior forms not only require a largeinvestment in materials, but involve expensive erection operations.Furthermore, where the walls are to be erected in an excavation belowground level, after removal of the forms, back filling normally isrequired at the excavation ground side of the wall.

Objectives of the invention are to provide a new procedure for erectingconcrete wall structures which eliminates the expense and cost oferection of fabricated wooden or metal forms; which eliminates the useof rigid forms; which utilizes relatively flexible form means which maybe left when desired in position after the concrete poured in thecavities provided by the forms has set; and which solves problemsexisting in the art and obtains the new results indicated in a simpleand economical manner.

These and other objects are obtained by the methods, steps, procedures,parts, constructions, arrangements,'com binations and subcombinationscomprising the present invention, preferred embodiments ofwhichillustrative of the best mode in which applicant has contemplatedapplying the principlesare set forth and illustrated in the accompanyingdrawings and which are particularly and distinctly pointed out and setforth in'the appended claims.

One concept of the present invention involves the method of forming wallstructures of concrete or a similar liquid setting material by providinga plurality of form support means, providing relatively flexible formmeans, attaching the relatively flexible form means to the form supportmeans in a predetermined manner to form a cavity, and filling the cavitywith a liquid material capable 3,468,088 Patented Sept. 23, 1969 ofsetting. It is also contemplated that predetermined surface shapes maybe provided by stretching the relatively flexible material through theweight of the cast material so that the material occupies a spacesomewhat larger than the cavity provided prior to filling.

Another concept of the invention involves providing, in apparatus forforming wall structures and the like, a plurality of form supportmembers having a generally H- shaped cross section. Such members areprovided with .a plurality of flanges extending inwardly from each ofthe H-legs, to retain in association with rod means, a relativelyflexible form member that extends between adjacent H-shaped supportmember. Other .form members may be placed in association with theflexible form member to form a cavity to be filled with a liquid settingmaterial, such as cement or concrete.

By way of example, the improved apparatus and methods are illustrated inthe accompanying drawings forming a part hereof wherein like numeralsindicate similar parts throughout the various figures and in which:

FIG. 1 is a fragmentary perspective view of a wall structure formed inaccordance with the principles of the present invention;

FIG. 2 is a cross-sectional view, partly in elevation, of the wallstructure of FIG. 1;

FIG. 3 is a fragmentary plan view, partly in section, of the wallstructure of FIG. 1;

FIG. 4 is a perspective view of a swimming pool in process ofconstruction illustrating one method of use of the wall structure of thepresent invention;

FIG. 5 is a fragmentary perspective view of a second embodiment of wallstructure of the present invention;

FIG. 6 is a fragmentary plan view of the wall structure shown in FIG. 5;

FIG. 7 is a fragmentary plan view of a third embodiment of the presentinvention;

FIG. 8 is a fragmentary plan view of another embodiment of the presentinvention;

FIG. 9 is a fragmentary plan view of a further embodiment of the presentinvention; and

FIG. 10 is a fragmentary vertical cross section, partly in elevation, ofa floor surface constructed in accordance with the principles of thepresent invention.

The improved wall structure shown in FIGS. 1 through 3 illustrates areinforced wall structure for a swimming pool or the like. FIG. 4generally illustrates a swimming pool in construction which may have thereinforced wall shown in FIGS. 1 through 3. In FIG. 4, 20 illustratesgenerally an excavation of the general size and shape of the swimmingpool, although slightly larger in length and width than the finishedpool size, and includes a shallow portion 21 and a deep portion 22. Thewall of the swimming pool may be provided by utilizing a continuouslength of fiber glass sheeting which is placed into the excavation priorto forming the bottom surface of the swimming pool from a material suchas reinforced concrete.

In one procedure of constructing a swimming pool the concrete bottom ispoured, after arranging the sidewall in the desired location, and theconcrete bottom is allowed to set. Back fill material is then placedbetween the space between the outside surface of the wall and theexcavation. A suitable coping material may then be placed around theupper edge of the wall and, if desired a concrete apron may be pouredaround the swimming pool perimeter.

-The improved wall structure of the present invention may be used toconstruct a reinforced swimming pool wall and such construction is shownin FIGS. 1 through 4. The continuous sheet of fiber glass material isindicated in FIGS. 1 through 4 by 23, and a series of channel members 24may be preattached to wall 23 at predetermined spaced intervals. Onesurface of channel 24 may be provided with a series of dovetail grooves25 so that channels 24 can be cemented to wall 23 with an epoxy glue in1t{he equivalent, the dovetail grooves providing an inter- In accordancewith the present invention, a series of H- shaped form support means 26are placed in channels 24. H-shaped members 26 have a pair of outwardlyextending flange means 27 which correspond to and interlock with a pairof inwardly extending flange means 28 formed integrally with channelmembers 24. H-shaped support member 26 also includes a pair of inwardlyextending flanges 29 which forms a pocket or groove that extends theentire length of member 26. A continuous length of relatively flexibleform means or sheeting 30 may then be placed to extend along the entirelength of the wall structure. A portion of the sheeting 30 is placedwithin the pocket of the H member and a rod means 31 is inserted in thepocket to retain the sheeting 30 therein. Sheeting 30 may be placedaround the entire perimeter of the wall and extends between adjacent Hmembers 26 and is retained in each H member 26 by a rod 31. A cavity isthereby formed by adpacent H members, wall member 23 and flexible formmeans 30. The position of the sheeting 30 at this stage of constructionis indicated in FIG. 3 by a dot-dash line.

Concrete or any other suitable material is then poured into the pocketand is indicated by reference numeral 32. The weight of the concretematerial poured into the pocket will tend to bulge the flexible formmeans 30 to a position shown in full lines in FIG. 3. After the concretehas set, the sheeting material may be removed if desired by removingrods 31, however, it is not necessary to remove the sheeting materialfrom the wall structure.

A swimming pool wall may be formed in accordance with the presentinvention by placing the relatively stiff fiber glass wall member 23 inan excavation, placing the series of H members in the previouslyattached channel members, placing the relatively flexible sheetingmember 30 in a position extending between adjacent H sections andretaining the same in position by placing the rod members in the Hmember pocket and pouring concrete material into the cavity formed bythe H members, wall member 23 and sheeting member 30. The completedswimming pool construction will include a swimming pool bottom 33 whichis normally formed of concrete reinforced with wire mesh. A retainingrod 34 may be utilized to hold the bottom portion of Wall 23 in positionprior to pouring the concrete bottom. Rod 34 may extend through a holeformed in the bottom portion of wall 23 and extend into the side of theexcavation. The completed swimming pool wall may also include coping 35which may be attached to the upper edge of wall 23 by any suitablematerial or method, such as a T-shaped member 36. Perforated steelstrapping 37 may also be attached at the upper edge of wall 23 to tie inthe upper edge of the wall to a concrete apron 38 which may be providedas a part of the swimming pool construction. After the pool bottom hasbeen poured and after completion of the vertical concrete portions 32,but prior to pouring the apron, back fill may be placed between thefinished wall and the excavation.

The wall construction just described utilizes, in accordance with thepresent invention, a relatively flexible sheet material as a portion ofthe form for constructing the concrete reinforcing members 32. Wall 23is, with respect to sheeting 30, relatively stiff, although it isflexible enough to conform to the shape of the finished swimming pool.

The finished surface formed by the concrete as poured will have onesurface generally curved due to the outward bulge caused by the weightof the concrete on the relatively flexible sheeting material 30.Sheeting material 30 which is preferably polyethylene or thermoplasticmaterial, can be reinforced by incorporating nylon meshing or it can bemade from some other suitable material. Thus, the strength of thesheeting can also be predetermined so that if desired the sheeting maybe strong enough to confine and hold the weight of the cement withoutany bulge and a flat surface would, therefore, result for the finishedwall construction.

The wall construction described provides a substantially stronger wallthan the wall member 23 would providealone. The wall is, therefore, ableto withstand the pressures which are exerted upon a swimming pool wallby the surrounding below-grade material, which pressures are far greaterthan the pressures exerted by the water in the pool, and are thereforethe major consideration in such'construction.

A second embodiment of wall construction is illustrated in FIGS. 5 and'6. An above-grade wall is illustrated and may be constructed upon acement footer 39. In accordance with the present invention, the H-shapedmembers 26 are placed vertically in the ground in the trench which hasbeen dug for footer 39 prior to pouring footer 39. The footer may thenbe poured and allowed to set. The polyethylene sheeting material 30 isthen placed extending along one edge of the H-shaped members andretained by a rod 31 in the same manner as described above. The H-shapedmembers may also be provided with a third pair of flange members 40which extend inwardly. A second pocket is thereby provided in which asecond sheeting member 30 may be retained. A concrete form is thusprovided by adjacent H members and the two opposite portions ofpolyethylene sheeting 30 and is shown in the dotted lines in FIG. 6.Concrete may then be poured into the cavity thus provided. Dependingupon the predetermined strength characteristics of the sheeting 30, theweight of the concrete will tend to bulge from the sheeting to theposition shown in full lines in FIG. 6. After the concrete has set, rods31 and sheeting 30 may be removed to provide a concrete wall 41. Ifdesired, a surface finish such as paint may be applied to the wall afterremoving the form means 30. If desired, a textured appearance may begiven to the partially set concrete by working the surface of theconcrete through the sheeting 30 with a masons trowel.

In this embodiment, as in the embodiment described above, the H-shapedmembers become an integral part of the wall construction. The H-shapedmembers may be provided with a fourth set of flange members 42 whichextend a small distance into the concrete to provide an interlockbetween the H members and the set concrete.

If desired, a strip of capping material may be placed in the H memberpocket to give a pleasing or desirable appearance to the entire wallsurface, by covering up the groove formed by the H member pocket.

If desired the method and apparatus of the present invention can beapplied to build walls of substantial thickness. To construct suchwalls, a plurality of H- shaped members may be placed back to back asshown in FIG. 7 and connected together by double channel members 43. Thedouble channel members 43 are constructed in cross section toaccommodate the outwardly extending flanges 27 which are formed as apart of the H-legs of the H members 26. A special H member 44 havingoutwardly extending flanges 27a at both ends of the pair of H-legs isused to connect adjacent H members 26 into a unitary form support. Thus,any number of H members may be connected together in a similar manner toobtain the desired wall thickness.

After placing the support members in the proper posi tion flexible formmaterial 30 may be placed at a position extending between adjacent setsof H member units. Form means 30 is shown in dotted lines in FIG. 7 andis retained in the channel or pocket formed by the pair of H-legs andflanges 29. Flexible form means 30 is retained in the pocket byinserting a rod 31 through the entire length thereof in the mannerdescribed above. After the cavity, which is illustrated prior to fillingin dotted lines, is filled, the weight of the filler material will bulgethe flexible form means 30 to the position shown in full line. As in thepreviously discussed embodiments, the form means 30 can be made,although flexible, strong enough so that the weight of the filler willbulge the sides outwardly only slightly as opposed to the bulge shown inthe drawings.

FIG. 8 illustrates a wall similar to that shown in FIG. 7. However onlytwo H units are required to obtain the desired wall thickness. Themethod of construction of the basic wall portion shown in FIG. 8 issimilar to that shown in FIG. 7 and includes a pair of H members 26 backto back and connected together by a double channel member 43.

A wall end is also illustrated in FIG. 8 in which an H member is placedat right angles to the position of the H members used to support theflexible form means 30 for the wall surface. In FIG. 8 the end H member26 becomes completely imbedded with and surrounded by the fillermaterial 44. After filler material 44 has set, the flexible form means30 may be removed. The slot extending the entire height of the wall maybe used for attaching capping means or the like, or if desired gates ordoors may be attached thereto.

FIG. 9 illustrates a wall construction in which the H members do notbecome an integral part of the wall. Thus, the series of H members 26are placed at the desired position with the sheeting material 30 placedat the inside of the H members rather than being stretched at and aroundthe outside as in the above described embodiments. The flexible formmeans 30 is retained in a manner similar to the above describedembodiments by rod means 31 being inserted in the pocket or grooveformed by the H-legs and the inwardly extending flanges. In thisembodiment of the invention, the H support members may be removed afterthe cement or other filler material has set.

The surface of the wall thus provided will be free of any grooves andwill be a continuous, unbroken, smooth surface. At the position on thewall where the H mem bers 26 were located, a slight ridge might existdue to the small amount of concrete that would enter the portion of theH-support member adjacent the flanges and rod means. If desired, thismaterial could be chipped away to provide a completely smooth, uniformsurface.

In the embodiment shown in FIG. 9 it is possible to provide a secondoverlying surface by placing a second sheet means 60 to be retained inthe H members 26 by a second series of rod means 61. Thus, a secondcavity 62 will be provided between the H members 26, form means 60 andform means 30. This cavity may then be filled with some suitable finishmaterial such as plaster if desired. If such a construction is used theH members 26 would become an integral part of the finished wall.

FIG. 10 illustrates the principles of the present invention as used toconstruct a floor surface. In FIG. 10, 63 indicates an I-beam upon whicha series of channel members 62 may be attached. H-support members 26 maybe retained in channel member 64 by sliding into channel members 64.Flexible means 30 may be laid across the top of H members 26 andretained therein by rod members 31 in a manner similar to the methodsused for vertical walls described above. Concrete or any other suitablematerial 65 may then be poured on top of flexible form means 30 andallowed to set. A strong rigid floor of concrete can thereby be providedin a very simple, cheap and economical manner.

In the foregoing description the flexible form means has been describedas polyethylene sheet material. Such material can be reinforced withnylon mesh as indicated or by any other suitable or convenientreinforcing material. Similarly, the sheeting material can be anyflexible, relatively strong, material such as canvas, metal foil or anyother material which has the desirable and necessary characteristics.

H-support members 26 are preferably formed from extruded aluminum, butthese members, however, could also be constructed of any suitablematerial such as plastic or the like or any other material depending onthe strength desired and the ultimate nature of the wall construction.

Further, in the foregoing description the filler material has beendescribed as concrete. It should be understood that other settingmaterials such as plastic foam may be used with equal effectiveness.

One important aspect of the present invention is the provision of a formfor pouring concrete wherein at least one of the form surfaces isprovided by a relatively flexible form means. Another important aspectof the invention is the provision of the flexible form support means andthe manner in which the flexible form means are retained by the formsupport means.

When using polyethylene sheet material as the flexible form means,several important advantages result. First, the form means isconstructed of such inexpensive material that it is not normallynecessary to be concerned with the ultimate recovery of the form afterthe wall has been poured. Thus, the form itself can remain at the siteof the wall construction after the wall has been built unless it isdesirable to remove the form for aesthetic reasons.

Secondly, polyethylene sheeting is normally translucent and any voidswhich might exist in the poured concrete can easily be seen and remediedby vibration of the concrete in the usual manner.

Wall constructions embodying the apparatus of the present invention andconstructed in accordance with the methods of the present invention canbe built very rapidly and with comparatively little expense.Accordingly, the present invention provides new appartaus and proceduresfor constructing walls or reinforcing walls without necessitating alarge capital investment for form materials and in which the forms maybe erected in a much easier manner and with much less time than isnormally required to erect the usual concrete forms known in the art.

In the foregoing description certain terms have been used for brevity,clearness and understanding, but such terms are used for descriptivepurposes and are intended to be broadly construed.

Moreover, the description and illustration of the invention and the newprocedures and apparatus are by way of example, and various products maybe used and procedures employed to accomplish the fundamental conceptsof the invention without departing from the principles set forth.

Having now described the invention or discovery, the principles of theinvention, the characteristics of the new apparatus, the manner in whichthe new methods may be carried out and the advantageous new and usefulresults obtained thereby; the new and useful steps, parts,constructions, elements, combinations, subcombinations and mechanicalequivalents thereof obvious to those skilled in the art, are set forthin the appended claims.

I claim:

1. Wall construction including a first form means of elongatedcontinuous semi-rigid sheet-like material having opposite side surfaces,one of the surfaces forming a surface of the wall, first retaining meansmounted on the other surface and located at spaced intervals along theform means, form support means retained by the retaining means, thesupport means having an elongated re-entrant groove extending generallytransversely of the form means, second flexible sheet-like form meansextending between adjacent support means, second form retaining meansmounted in the re-entrant groove to retain the flexible form means inthe groove, the first and second sheetlike form means and adjacentretaining means and support means defining a cavity, and said cavitybeing filled with a settable wall-forming material.

2. Wall construction as defined in claim 1 in which the settable wallforming material is concrete.

3. Wall construction as defined in claim 1 in which the first retainingmeans includes a generally channel-shaped member premounted on thesecond surface, and in which the support means includes an elongatedmember having flanges adapted to engage and be retained by the retainingmeans channel.

4. Wall construction as defined in claim 3 in which said support meansgroove is spaced a distance from the flange means retained by theretaining means, and in which the second retaining means is elongatedrod means mounted in the groove to retain the flexible sheet-like formmeans in the groove.

5. Wall construction as defined in claim 1 in which said secondretaining means includes elongated rod means mounted in the groove, andin which said support means includes flange means retained in the firstretaining means and in which the re-entrant groove is formed by anelongated generally channel-shaped member having a channel openingsmaller than the diameter of the rod means.

6. Swimming pool construction including a bottom, a side wall formed ofa continuous sheet-like strip of waterproof material and having oppositeside surfaces, one of the surfaces forming the surface of the side wall,first retaining means premounted on the other side surface at spacedintervals along the side wall and being vertically disposed andextending substantially the entire height of the side wall, supportmeans having an elongated re-entrant groove retained by the retainingmeans and extending substantially the entire length of the retainingmeans, a continuous sheet-like flexible form means extending betweenadjacent retaining means and support means, second retaining meansretaining the flexible sheet-like form means in adjacent support means,the side wall, retaining means, support means, and flexible sheet-likeform means defining a cavity, and the cavity being filled with side wallreinforcing means.

7. Swimming pool construction as defined in claim 6 in which said sidewall reinforcing means is concrete.

8. Swimming pool construction as defined in claim 6 in which said sidewall is located and mounted on edge on the bottom.

9. Swimming pool construction as defined in claim 6 in which said secondretaining means includes elongated rod means mounted in the groove toretain the flexible form means in the groove.

10. Swimming pool construction as defined in claim 9 in which said firstretaining means includes a generally channel shaped member adapted toreceive and retain the support means.

References Cited UNITED STATES PATENTS FRANK L. ABBOTT, Primary ExaminerP. C. PAW, JR., Assistant Examiner US. Cl. X.R.

